Process for producing magnesium metal



Aug.3 1,1943. AL DQERNER 2,328,202

PROCESS FOR PRODUCING MAGNESIUM METAL Aug- 31, 1943. A DoERNl-:R 2,323,202

' l P RocEss FoR noDUING MAGNESIUMVMETAL' Filed Dec; go, 1940 sheefs-sheeng cv llNvlaNToR HENRY A. DoEn NER s s ATTORNEY Aug, 31, 1943. H. A.- DOERNER PROCESS FOR PRODUCING MAGNESIM MTAL Filed ned. so, v1940 5 sheets-sheet 3 lNvENToR HENRY A. DDERN I l ATTORNEY Au'g. 31, 1943. H. A. DoERNER PROCESS 4FOR PRODUCING MAGNESIUM METAL Filed Dec. 30, 1940 5 Sheets-Sheet 4 A'INVENTOR f HENRY. A. DOERNER I ATTORNEY 'nesium oxide by carbon,

ladened Aoil is removed -distilledoff at preferably at a temperatln'e boiling point, say 1000 C. ,promptly condensed, preferably at'a temperah n Patented Aug. y

UNITED y STATE s linrrEN'r OFFICE PROCESS Fon PRODCING lMAGNESIUM METAL VHenry A. Doernen'Pullman, Wash.

Application December 3 o, 1940, serial No. 372,293;

19 claims. '(01. 'i5-sw) The present invention relates to an improved process for producing magnesium volves the electrothermal reduction of magand the subsequent steps to obtain the magnesium metal in solid mass form of high purity.

According to my invention a mixture of carbon and magnesium oxide is reduced togmagnesium vaporand carbon -monoxide in a'thermal reduction furnace, at a temperature of approximately 2000910. preferably by means of an electric arc. The magnesium vapor and carbon monoxide issue asa blast from 4the reduction furnace directly into a cooling flueinto which is atomized a controlled quantity of a readily volatile inert liquid containing a suitable proportion of hydrocarbon oil having a boiling point above the constant temperature of the cooling luid which is maintained at about 200 negative latent heat of vaporization of the vola'- tile liquid supplied. Thus the magnesium vapor metal and iny C. principally by the tilling'and cndensingbeing done in an inert atmosphere.' drawn off and cast ,in any suitable solid form. Preferably, the distilling of the magnesium is conducted vin a continuous series of separate charges, and the exhausted briquettes are se.

rially discharged to make way for recharging.

In the thermal reduction of magnesium oxide with carbon, the reaction occurs in accordance with the equation:

` and since the thermal reduction temperature is is immediately shock co'oled to well below`the melting point of the metal so as to substantially prevent the reoxidation which wouldotherwise occur in the presence of the inherently existing carbon monoxide. almost atomic particles and is entrapped by the atomized hydrocarbon oil ,which serves as a vehicle to carry the magnesium and other inherentiy existing studs. through a suitable sep,

arator where the vaporized portions of the cooling liquid and carbon monoxide are discharged into a suitable condenser, andthe magnesium to a retort and the oil a temperature below the melting The magnesium condenses in y far above the boiling point of magnesium, the metal is producedinthe vapor form. 1n actual practice, the reduction products are always intermingled with some iinely divided solids. These solids are mainly MgO and C and are due to particles of the original charge which are carried out of the reduction furnace without reacting, and also due to partial reversal of the reaction, occurring at the outlet of the reduction furnace, together with such impurities as may exist. These solids in ne powder, are

intermingled with the Mg vapor and CO, and it is utterly rimpossible to obtain isolated Mg by shock cooling of the reaction products.

Any form of .shock cooling Mg in almost atomic particles intermingled with' the other finely divided solids, and the Mg can d not be successfully recovered by distillation unpoint of magnesium and in an inert atmosphere,

as for instance,

the vapors-and gases produced Distilling 'off the hydrocarbon oil, provides a Vporous mass of the existingsolids throughout` which is a dispersion of pyrophoric magnesium and a small amount ofthe hydrocarbon oil whichy fails to olf. Preferably, this oil distillation is conductedI in molds -so as to vform molded briquettes and thus lessen the possibility of dust contamination during theV subsequent distillation of themagnesium. Y

These porous briquettes containing the"nely divided magnesium are then discharged into another retort, and 'the magnesium is distilled, slightly below its ture slightlyjabove the melting'point; the disthe distillation of the hydrocarbon oil willv .suiice for the requirements when air is excluded.

' cooling liquid that it will be exceedingly diiiless somejform of bonding is employed, so as to obviate dust being carried over with the metal vapor, A

-If the Mg is shock cooled by a liquid essentially non-volatile at the cooling temperature,` there will be such an extreme excess of. the

cult and expensive to separate the excess of liquid so .as `to proceed further with recovering the Mg by distillation.

To form the finely divided Mg and other solids into a fluid-paste which can" be satisfactorily processed, there is Arequired about two pounds of hydrocarbon 011 to each pound vof total solids collected therein, the ratio depending upon the existingvproportion of 4non-metallic contents.

There is no Aknown hydrocarbon. oil which will and the metal is produce. the required temperature reduction .when atomized into the thermal reduction p rod-v ucts at suh a minor rate. In fact it'would re-.

quire more than sixty times that amount of hydrocarbon oil when substantially non-volatile at a satisfactory cooling temperature, nd the same *55 'would be true of any other liquid hydrocarbon l'l'lrie molten metal can then be.

will condense the substantially non-volatile at the cooling ternperature employed. It is commercially prohibitive to attempt to separate Vsuch an extreme exloess of liquid by centrifuge, or otherwise.

For these reasons, the present invention accomplishes the shock cooling by the vaporization of a hydrocarbon liquid sprayed into the reaction products at a controlled rate to produce a cooling temperature which will provide a dew point at which the unvaporized portion of the hydrocarbon liquid will be about twice the weight of the total solids collected therein.

Various cooling liquids may be employed, provided that they are chemically inert to the existing conditions. Liquid hydrocarbons are particularly suited for the purpose, provided that their boiling point range is within the limits which will afford an adequate cooling temperature at which the unvaporized portion can be controlled to meet the previously stated requirements. Preferably, the unvaporized portion should contain sufiicient carbonizing oil to later afford satisfactory bondingof the solids collected bythe shock cooling, because otherwise there will be considerable dusting which makes difficulty in recovering the Mg by distillation. 1

To illustrate one example, one part of lubricating oilS. A.' E. 30 and sixteen parts of gasoline will suffice for the required purpose. This mixture is sprayed into the reduction products at a n controlled rate in accordance with the output of the reduction furnace, so as to produce a. cooling temperature of say 190 C. This will vaporize practically all of the gasoline and practically none of the lubricating oil, and there will be about two pounds of oil to each pound of. Mgand other solids collected therein, and if thisproves to be more oil than is required, the rate of spray can be reduced so as to supply less oil, and also the temperature will rise in accordance with the decrease in the amount of gasoline -supplied for vaporization. Conversely, if more oil is required for proper uidity, the. rate of spray can be increased to supply more oil, and in this instance the temperature will decrease in accordancewith the increase in the amount of gasoline supplied for vaporization. If necessary, the rate of spray can be increased until the temperature is decreased sufciently to afford a dew point for the heavier fractions of gasoline and thereby cause a portion of them to condense. However, such a. situation is merely illustrative and need-never occur, it is mentioned for the purpose of illustrating the possibility of condensing different fractions of the cooling liquid. As for instance, instead of the described gasoline and oil mixture, there may be used some low priced hydrocarbon liquid having severa1 constituents and a boilingcause the boiling points of these various fractions are much closer together than was the case in the previous mixture of gasolineA and oil, and therefore each temperature drop will afford a dew point for an additional fraction.

- The stove oil is sprayedV into the thermal reduction products at a controlled rate to produce :s cooling temperature of say 185 C. to afforda dew point at which the unvaporized heavier fractions will be about two pounds to each pound of Mg and other solids collected therein. Then each increase in the rate of spray will reduce the temperature and increase the percentage of unvaporized constituents, so that each increase in the rate of spray will have an accumulative effect on the percentage of unvaporized constituents. Thus the unvaporized portion used for collecting the Mg and other solids can be varied considerably with but slight changes in the cooling temperature.

In this manner the spray rate can be set at whatever Volume will produce a temperature which will afford the proper amount of `unvaporized liquid for properly carrying out the process. and the ratio of unvaporized liquid can be repeatedly altered according to requirements, with but minor changes in the cooling temperature. The control can readily be made. automatic by a thermostat, and reset as often as occasion requires, to meet existing conditions.

This improved method affords the advantage that the shock cooling is accomplished by vaporizing about 94 percent of the cooiing liquid, thereby affording collection` of the Mg and other solids in about 6 percent of the total cooling liquid employed, so as to form a uid paste which can be quickly separated from the CO and hydrocarbon vaporsso that the-latter can be condensed to liquid for repeated use. The fiuid paste is conducted away as fast as it is formed, and is in condition for immediate briquetting, vwithout; resorting to such procedures as centrifuging or filtering to reduce the quantity of liquid. The hydrocarbon oil is distilled off during the briquetting and condensed to liquid for repeated use. The briquetting proceeds at the same rate as the output from the reduction furnace, and then the distilling of the Mg follows in immediate sequence and at the same rate.

Thus the shock cooling, collecting, separation, bonding, and distilling, areV united into a continuous process which is accomplished in a reguf lar sequence of steps without interruption, and

whereeach step is oorelated with the other steps.

During the briquetting and distilling of the Mg, there occurs some thermal decomposition of the hydrocarbons Which'results in the formation of gases such as hydrogen and methane and these gases are utilized to afford an inert atmosphere during the briquetting and distilling, after which the gases are collected 'as a by-product. Thermal decomposition of hydrocarbons at the cooling zone also-produces some hydrogen and methane intermingled with the existing CO and ,these gases are collected as a by-product having considerable fuel value.

The present process has been discovered and perfected by extensive experiments and experience, by actually operating the process and successfully producing magnesium metal in solid cast 1forixhln with a high state of purity and a bright us re.v

The accompanying drawings illustrate the best mode that I have thus far devised for carrying the process vof myinvention into actual practice. A consideration of these drawings in connection with the following specification relating thereto,

will 'afford a. full .understanding of the variousv details relating to the coordinating of the'coolon the line reduction products issue as a .and the Mg and 2l and is automatically and actuated by the motor marient gases as a part of the process.

Fig. 1 diagrammatcally shows the general organization of equipment suitable for accomplishing the process.

Fig. 2 is a vertical section of the major portion of the equipment.

Fig. 3 is a vertical section ofthe two retorts with part of the heatl insulating material removed to disclose. the condenser.

Fig. 4 is a vertical transverse section taken 4-4 of Fig. 3 and enlarged to represent proportionate size relative to the showing in Fig. 2.

Fig. 5 is an enlarged horizontal sectionl taken on the line 5-5 of Fig. 2.

Fig. 6 is a perspective view ofV one of the mulits lowermost position to movable along the electrode I6 so as to` accommodate the advancement thereof and the .feeding in of a new electrode I6' without interrupting the current. The insulated clamp I1 is provided for convenience in affording a new bite on the electrode each time the carriage is raised `from start another descent.

The electrode 26 is secured to the frame of the reduction furnace and connected to the source of power. the feed port for This electrode 26 is hollow and provides the reduction furnace. In the present instance, Athere is collectively indicated at D, a hydraulic feed mechanism which is automatically operated by electromagnetic valves. The charge from the hopper B is packed in metal cartridges such as 21 and21 which have both ends open. An electric vibrator I0 is' used to tightly pack the dry powdered material in the cartridges which are arranged in an endless train tiple briquette molds carried on palred sprocket.v f

chains. I

Fig. '7 is a perspective view of one of the series of cages from which the magnesium is distilled. First referring to the illustrated equipment broadly, there is 'shown a thermal reduction furnace E provided with an automatic feed mechanism collectively indicated at D, and supplied with material from reduction takes place in this furnace E and the blast through the flue F where they are shock cooled by the vaporization of the major'portion of a spray of liquid hydrocarbons fed through the pipe 28, and the unvaporized hydrocarbons entrap the Mg and other solids and this mixture vissues as a fine mist into the separator G from which the mixture is promptly discharged as a fluid paste into the vertical pipe H 4and conveyed to the heated retort L where the hydrocarbons vare other 'solids formed into briquettes which are then fed into the heated retort M where the Mg is distilled off and then condensed as a highly pure metal.

i The scrubber S, reservoir R, and condensers the hopper B. The thermal,J

distilled off and passed along a track from the packing position to the feed port of the reduction furnace and back again' on a return track by opposite movements of the reciprocating carriages 2 and 3 supplemented by the necessary cross movements which are accomplished by levers (not shown) mechanically actuated by the movement of these carriages which are operated by the hydraulic rams 8 and 9.

The carriages 2 and 3vare slidably mounted in guideways and each of these carriages consists of two separately movable sections which iit around each cartridge, and the outward movementof each carriage separates its two sections to provide for inserting and removing the cartridges.

'Ihese two carriages alternatelyqmove outwardly from their illustrated positions, to close the rcy hopper and a filled cartridge under the feed port C-C afford means for recovering the vaporized tion in regular sequence, without interruption and delay. The preferred vmode of accomplish ing each step will now be described in detail.

Thermal reduction The thermal reduction furnacemay be of any suitable typ, and the charge of MgO and C may be fed thereto in any suitable manner, either dry Aor admixed with a liquid hydrocarbon. As shown in Fig. 2 the reduction'l furnace E consists of a refractory mule 24 surrounded by loose packed refractory, suitably water jacketed as indicated at23 and sealed by a water jacketed cover 2| electrically insulated as indicated at 22. electrode .I6 passes through the insulated cover advanced by a carriage mechanism which is collectively indicated at A by a-worm reduction'unit 2|! lturned I9 which is driven in accordance, with the potential across thel arc in the reduction furnace.. Suitable power source is connected to the sliding l'friction terminal: I8 whlchis freely The.

-ated by air pressure and `by-pass so as to supply of the reduction furnace where the charge is very gradually injected into the furnace by the ram 4.

The rams 8, 9, and 4 are supplied with pressure through the electromagnetic valves II, I2, I3 and I4, the iirst three of which are suitably connected to an air pressure line and the last to oil under pressure from the pump P for Which it forms a by-pass in'the manner illustrated. The rams 8 and 9 are each provided with an oil reservoir such as 0 which is subjectyto the air pressure from their respective valves, each'of which has a discharge line for conducting any oil froth t-o a suitable res ervoir not shown. One side of each ramis oper-` the opposite side by oil under air pressure. This provides 'a more even control than would otherwise be afforded by air pressure alone.

The injecting ram 4 is attached to the carriage 3 and connected to its pressure lines by flexible tubing so as to accommodate its movement with the carriage 3. l

'I'he various movements ofthe rams operate `electrical switches whichv valves'either directly or else through a relay I5. The circuits are so arranged that when the filled cartridge 21 is registered in -position under the feed port as -illustrated',a switch is operated to cause the electromagnetic valve I4, to closel the hydraulic pressure from the pump P to very gradually raise the injecting ram 4 so that its plunger 5 will gradually push the charge out of the cartridge and into the feed port ofthe reduction furnace.

control the magnetic The completed stroke -operates a switch which causes the magnetic valve I fI4 to open the by-pass and leave the ram 4 at its ascended position; and this same switch also opcrates the magnetic valve I3 to actuate the ram A 9 so that the carriage 3 and/fam 4 carried thereby are moved -to the right until the upper plate of this carriage closes the feed port of the reduction `furnace, whereupon the carriage is halted by a mechanical stop, and an electrical switch operates the magnetic valve I I to quickly lower the ram 4 lwhich then operates a switch to cause the magwith the feed port of the reduction furnace, whereupon-the iirst mentioned switch is again operated to cause the magnetic valve I4 to close the 'Dy-pass so as to again raise the ram 4 to begin another cycle. This movement of the carriage 3 to the left also moves the train of empty cartridges towards the hopper. y A

The two sections of the carriage 2 are latched together and their movement begins when the carriage 3 reaches its illustrated position, at which time the switch which closes the by-pass valve I4, also operates lthe magnetic valve I2 to actuate the ram 8 to move the carriage 2 to the left and close the port in the hopper. This movement unlatches the sections and the outer section continues its movement to separate the sections and mechanically actuate a lever (not shown) to move an empty cartridge into place and push out' the iilled cartridge into the lline of travel. The full movement ofthis carriage operates a switch which causes the magnetic valve I2 to reverse the ram 8 and move the carriage 2 back to its illustrated position thereby moving the train of filled cartridges towards the reductisn'furnace and the empty cartridge in register with the open port of the hopper where it is subjected to the action of the electric vibrator I until the beginnjng of the next rising stroke of the ram 4. This vibration assures that each cartridge will be tightly packed .with thematerial from the hopper, thus vsubstantially eliminating the possibility of inclusions of air, andalso assuring a compact charge which can be effectively injected by the Shock cooling and separation held in fixed relation thereto. As shown in Fig.

this iiue F is water jacketed and its inner end 'is provided with a spray ring which may have Aand the ram 4 to the left and again in register l either one or two annular spray channels such as U and V each provided with a multiplicity of spray orifices opening into the flue F. In the present instance the spray channel V is shown connected to the pipe 2.8 which supplies liquid hydrocarbons under pressure from the reservoir R', a pump such as 30 providing the necessary pressure, and any suitable means may be provided to control the ow through the pipe 28, as for instance the hand operated valve 29 will sufflCG. l

The thermal reduction products consisting of Mg'vapor and CO, together with some MgO and C, issue as a blast from the reduction furnace E into the flue F Where they contact the multiplicity of streams of liquid hydrocarbons issuing from the orilices of the spray channel. This blast is suflicient to substantially atomize the liquid hydrocarbons, and complete vaporization thereof will take place until the supply through the pipe 28 is sucient to reduce the temperature suiliciently to afford a dew point for the heavier fractions of the liquid hydrocarbons supplied, as for instance stove oil. The flow through the pipe 28 is regulated so thata suitable percentage of the liquid is unvaporized, say about 5 per cent. The vaporized portions effectively reduce the temperature of the thermal reduction products, and the negative heat of vaporization of the sprayed liquid greatly reduces the amount of liquid required. Ths leaves the unvaporized portion disseminated and its effectively entraps the condensed Mg an/d other solids, and this mixture passes into the separator G as a mist which is forced out into the vertical pipe H as a iiuid paste, and the CO and vapo-rized hydrocarbons pass out through the pipe'49 to the scrubber S. Any suitable separator may be employed, but in the present instance the separator G is shown as aclosed vertical casing, heat insulated and having a vertical slot 43 opening into the Vertical pipe H. Rotatably mounted within this casing is a vertical shaft 38 having a number` of spiders such as 33 which support four blades such as 40.

plunger 5 of the ram 4. The feed port tocontainfour or live-of these tightly packed charges and thus there is provided :an Yeieciive air seal for `the reduction furnace. The pump P can be driven by a. variable sed motor conof the reduction furnace is of suicient length.'

trolled by asuitable rheostat and the rate ofv feedto the 'furnace can readily beregulated according tothe best operating conditions. v Y

This automatic feed device is preferable because it provides exceptional uniformity of the operation of the thermal reduction furnace and prevents fluctuations in the output of the therl must of necessity rise in mal reduction products- .Howeven any suitable form of feed device may be substituted for. thev disclosed embodiment, which is hereby acknowl- T his shaft and its blades are motor driven asindrcated at 45 and are turned at suilicient rate to urge the beforernentioned mist to the walls of and carry the coalescing globules around the casing untilthey escape through the open slot 43 into the vertical pipe H in the form of a uid paste'- This shaft 38 is driven at sufficient lspeed that the movement of the blades precludes any of the mist formng'a liquid in the bottom of the casing, where the shaft 38 is further-provided with a spider 44 which would urge Y any such condensate out through the lower part of 61e slot'43 and preventaccumulation in the separator. 1

The vaporized hydrocarbons and existing gases the separator, and pass out through the pipe 43 into the scrubber S. To

.assure complete separation ofthe niist from the vaporized `hydrocarbons'and gases, the spiders 3 9 are provided' with disks 4I and rings 42 -alternately arranged on the several spiders to serve as ballles to produce a zig-zag path -through the lseparator' G.

Mountedvin the upper part of the separator G potentiometer S4 carbon liquid to the flue F By providing the reservoir R with a hydrocarily be controlled by idraulic cylinder is a thermocoupie 31 temperature in the separator, so automatic control of the rate through the pipe 28 to maintain which senses the existing provide for as to of liquid flow a constant temperature and uniform relation with the output of the thermal reduction furnace This thermocouple is shown connected to the through which turned so as to vary trois the speed of the variable' which drives the pump 30 bon liquid which will readily the motor is the rheostatl 36 which conspeed motor `3| supplying the hydrothrough the pipe 28.

vaporize in the flue F to .produce a suitable cooling temperature .of say about 200 C. and leave portion sufficient to an unvaporized form a fluid paste with the finely divided Mg and other solids', the ratio of the vaporized and unvaporized portions can readthrough the pipe 28, either tO maintain a constant altering the rate of flow by automatic control temperature in the separator G or else by manually regulating the valve 29 in the `pipe 28, or by manually operating! a suitable rheostat to control the speed of the motor 3|. In 'any instance be determined by an inspection of the existing operation,

the requirements will of thefluid paste formed and careful judgment of the eiiiciency then the conditions can be appropriately altered as circumstances may `suggest and necessity require.

That is to say,

CII

that a deficiency in the collecting liquid may be corrected either by reconditioning the liquid in the reservoir R, or else temperature and rate of by altering the cooling spray according to requirementsv and according to the character of the liquid supplied from the v'reservoir R. Successful operation permits of reasonable latitude and there is n o necessity for frequent changes from a properly established ratio As was hereinbefore mentioned, there is always present in the output of the reduction furnace,

some MgO and carbon due to reversal of the reaction at the outlet orifice of the reduction furnaceand usually some impurities such as silicon and its compounds. to form a hard deposit block the output of' to provide an Such solids are inclined in the outlet orifice and the reduction furnace. To take care of this unavoidable condition, I prefer .automatic reamer as collectively indicatedat Z in l.Fig 5.. This reamer is driven by a motor, and a ram 'supplements the rotary movement bya reciprocating action which periodically enters this rotating -reamerinto the outlet orice of the reduction furnace and promptly withdraws it so'as not to appreciably -impedethe -output from the furnace. shown, this reamer passes tangentially through the separator G and axially enters the ilue F which is correspondingly positioned for this purpose.

eating action is sleeve 65. extending full length head 68 "of the cylinder. having a flange` 16 is rotatably sleeve and held by a nut 10 has an elongated shaft the cylinder-head 1| the tubular cured to the outer end 69-is a bit 15 having a reamer he As shownin Fig.v5, this rotary and recipro- 'accomplished by 64 with. a piston 66 having a providing ahyof the cylinder mounted in -the The motor 12 through ad 13 and lcarrying a pair of small propellers 14. From this description it will be seen movements of the'piston 66.

Pressure is alternately applied to opposite sides of the piston 66 through the pipes 11 and 18 by any suitable control such periodically operated, 'as for vinstance bya clock switch, so that the reamer head 13 periodically enters the outlet orifice of the reduction furnace and is promptly Withdrawn, the propellers 14 suflicing to remove any solids from the ue F.

When properly collected, the before mentioned MgO and C afford avery desirable bulking agent for briquetting the Mg, and for this purpose the unvaporized portion. of the hydrocarbon liquid should contain sufficient oil of a character to afford a suitable bonding agent when carbonized at a temperature below the melting point of Mg. However, if it is desired to resort to separately adding a bonding agent. the unvaporized'collecting liquid may be of the same character as the vaporized portion by supplying the reservoir R with a lighthydrocarbon and controlling the vrate of flow through the pipe 28 to produce a cooling temperature which will produce a dew point so as to preclude total vaporization.` No

advantage is seen in resorting to this variation and it is mentioned merely as a possible alternative.

Conveying 'I'he verticalpipe H is connected to the pump 41 driven by the motor 48, and the fluid paste. containingthe Mg, MgO, and any solid im purities, all suspended in hydrocarbon oil, is conveyed by the pipe 46 direct to a hopper 80 above cess of, oil-which would otherwise exist in the absence of the present processes which is particularly directed to avoiding that commercially impractical inaptitude.

. Brquettng' As shown in Fig. 3 the briquettng retort L con` sists of a horizontal tube 82 rectangular in cross i '64 and slidably mounted through theforward VAtubul'ar bearing 69 .section and heated by electrical resistance elements as indicated at 83, and suitably heat 'insulated. Passing through this retort,'is an endless conveyor having paired chains such as 86 which are trained around paired sprocket wheels such as 84 and motor driven at the opposite end by paired sprocket wheels such as 81. Pivoted to these sprocket chains is a series of overlapping pans 85 each of which is formed with a number of basins such as Y for carrying the fluid paste 4through the retort so as to form briquettes molded to the shape of these basins. During the movement of each pan 85 around the drive wheels 81, the pan swings on its pivots to an inverted position where its swinging movement is abrupt ly halted by striking the bumper 88,'whereupon the briquettes drop intothe hopper 89. The return flight ofthe conveyor passes through the rectangular tube 9| which is provided with an expansion' joint as; indicated at 92. Theentire mechanism is enclosed air tight.

From the hopper the iluid paste is continuthat the bit 15 rotates with the shaft 61 and is reciprocated -by the as a magnetic valve ously fed into'the molding pans 85 by the motor driven pump 8| having a number of outlet nipples as indicated at K in Fig. 4 corresponding to the number of basins in each of the pans 85 which are shown in Fig. 6 as each having four basins.v

The pans being overlapping as shown, their travel and the feed from the pump 8| can `both be con tinuous, and theiiuid paste will readily find lits and portions thereof are carbonized to aiord a/ bonding agent for the briquettes. This heating forms some hydrogen and methane by thermal decomposition of the hydrocarbon oil, and -thes'e gases and the vaporized oil pass out through a pipe 93 into a condenser C' and this directional flow is assisted by recirculating these gases into the opposite en d of the retort through a pipe 95 from the motor driven pump 96 which is fed by the pipe 94 from the condenser C', thus forming a continuous circuit for the repeated utilization of the same gases which are derived from the process itself. The retort being originally supplied with a suitable gas such as methane or else hydrogen, any losses will be-fully replenished by thermal decomposition of a part of the hydrocarbon oil during the briquetting, and any excess of suchgases will pass through the 'pipe |33 into the meter N' and out through the pipe |35 to the `pump 33 of Fig. 2. 'I'he liquid condensate from the condenser C' is constantly returned to the reservoir R through the pipes 6|' and 6|.

Magnesium distillation y The molded briduettes are porous cakes of the existing solids throughout `4which is a dispersion of pyrophoric Mg and a small amount of hydrocarbon oil. These briquettes are preferably about the length of `a ngerand of suicient thickness" The Mg can readily be` curs without appreciable coalescing during the liquid state.

i The Mg can be distilled from these briquettes in any suitable manner; however, it isA preferable to avoid any procedure which causes crushing and pass the briqu'ettes through the retortf. The-retort tube 98 is iilled with a line ofcages s1. 1chfasfv |04 'whichhave large openings |05 in their lends Y for the'passageof gas throughs-the briquettes.l

during distillation. These cages are passed through theretort by a periodically-operatedghydraulic ram |08, which is mounted on thel housover the hopper |I'0 into which the exhausted briquettes `vare discharged. The bell gate |28 is used to drop the exhausted briquettes intothe hopper |21 from Which they maybe removed in any suitable manner, oneform of which is shown at |28. i

'Ihese exhausted .briquettes contain principally l Mg() and Cand since these constituents are the sameas the original reactants'. it is feasible to subject this dischargedmaterial to the described process and gain the Mg therefrom, vto thereby enhance the percentage of recovery. Of course such reprocessing requires adding suicient MgO to afford a proper ratio for thermal reduction. It is also feasible to rst grind these exhausted briquettes and subject the material to otation to separate any silicates or other impurities so that the reprocessing by thermal reduction will notresult in ,an accumulated percentage of impurities.

The cages |04 are individually returned to the adit end of the retort tube 98 by means of an endless conveyor operating in the casing |02 and housing |0I. This conveyor consists of a pair of sprocket chains such as Ill trained around a pair of Wheels such `as ||2 spaced apart on oppo-v site sides of the paired tracks |09, and these sprocket chains then pass through the horizontal casing |02 and are trained around a pair of drive Wheels such as ||3 and then under idler wheels such as l HI` and back through the casing to the Wheels l l2. These sprocket chains are connected by one or more cross barssuch as `||5 which serve -to drag each inverted cage through the casattrition, so as. to minimize the amount of dust carried overby the Mg vapors.

As shown'in Fig. 3 the Mg distilling retort M is connected'direct to the briquetting retort L byA the hoppers 89 andv 91 which are provided with the bell gate 90., This retort M consists of a horizontal tube 98 rectangular in cross section and heated by electrical resistance elements as indicated at |00. The adit end of the rectangular retort tube 98 is connected by an expansion joint 99 to the upper part of a. housing |0| which has its lower part connected to a horizontal casing or mechanically.

ing and into the housing 10| where the curved track IIB supports each cage untilit arrives in upright position at the adit end of the retort. The cross bar |I5 then passes on and moves a lever I l1 which makes an electrical `contact which operates a magnetic valve ||8 to actuate the hydraulic ram |08 to cause its plunger ||9to move the line of cages exactly one cage length. When the cross bar ||5 leaves the lever ||1 the magnetic valve I I8 reverses the ram and retracts its plunger out of the path of travel, where it remains until the next movement of 'the lever. As seen in Fig. 3, the second cage in line is positioned under the hopper 91, and the briquettes drop into the cage by gravity, and any stray briquettesI will 'be caught by the empty'eage already in position.` The bell gate 90 is used to keep the hopper 91 supplied with su'icient briquettes to completely ll each cage |04 so that the retort tube 98 is at all times completely filled with briquettes. This bell gate 90 is here shown as operated4 by a hand lever but it may very well' be automatically Aoperated either hydraulically At. the center of the retort 98 is a tube |22 which conducts the vapors to a heated dust separator |23 ih the manner best'seen in Fig. 4, a suction clean-out tube being indicated atv 24. The outlet neck |25 of this dust collector connects to the condenser W.

The briquettes contain some hydrocarbon oil,

dense the metal toa at the melting point of Mg,

however, the upper part of the leg, the vents a upper part of4 and the temperature of the retort M is sumcient to thermally decomposesubstantially all of this oil into gases, principally hydrogen and methane.`

To accelerate the distillation of the Mg and maintain a directional iiow of the vapors, each end of the retort tube is supplied with gas through the pipes |20 and |2| from the pump culation between the two retorts.

condensing 'Any suitable condenser may be employed to condense the Mg vapors as they issue from the retort M. The most desirable procedure is to iii-st condense the lmajor portion of the Mg as a .liquid so that it can betapped oi into molds, and to conductl the remaining vapors into a secondary condenser maintained at a temperature well below the melting point of Mg so as to consolid. 4That is to say, that it is well known that Mg vaporscan not be totally condensed to a liquid, because there is appreciable vaporization in the liquid state.

In a large plant, a number of retorts such as M could discharge their Mg vapors into one large master condenser supplemented by a secondary condenser. In this way, various expedients could be adapted to afford convenience in accomplishing condensing of the'Mg in two stages.

In'the present instance, there is shown. at W a U-tube condenser andeach leg of the U-tube is connected to the pi'pe |30 which leads to the lter |3|, a valve |29 being ternate use of each leg. As here shown, each leg is provided with a number of heating .elements such as |36. Any suitable control can be used to maintain the lower portion of the condenser is essential that this portion bel .heatfinsulated;

part of the condenser requires no heating' during condensing and therefore the upper heating elements are used only for melting down thev condensed Mg. To afford eilicient condensing it isv advisable to provide some meansfor air cooling the upper part of the condenser."'This airvcoolingmay be accomplished in various ways, as for instance there isshown in Fig. 4 a casing |31 ofheat insulating material vented 'at the top as 'indicated at |40 and vented at the bottom as indicated at. I 39 and providedv with a closure \sleeve |30. The bottom vents |39 are closed during the melting vdown of thel conf 1 densed metal, after which they areopened to yprovide air cooling by convection.

traces of theY Mg condense as a powder, some of which passes out with the gases through the pipe and is collected in the lter |3| from which the gases are vreturnedv thel pump 96 for recirculation through -the pipes |20 and |2|. pipe |33 into the meter N' and then through pipe |35 to the pump 33 shown in Fig. 2.'-

The lower part ofthe condenser is provided the - with 'a pipe |4I through which the condensed oif into any' suitable re'- ceiver. A heating element |42 is provided to heat the pipe |4| for the purpose of tapping. For melting down the solid magnesium in the-upper |39 are closed andthe magnesium is tapped and for this purpose it The lastv by the pipe |32 to feed.

, Any excess gases'pa'ss through thel present spiral passage so as to free globules of liquid. shown to afford al- I presentl process, these gases contain considerably the leg heated to the required temperature, it of course being understood thatthe v alve |29 is previously turned4 to clse'that leg and open vthe other.

Recouery of liquid hydrocarbons As hereinbefore mentioned, the hydrocarbon vapors and gases from the separator G pass through the pipe 49 to the scrubber S. This scrubber may be of any well knowny type.. In the present instance the scrubber S is shown with an open lower end communicating with the reservoir `R which is filled with the hydrocarbon liquid which supplies the-cooling sprayv through the pipe 20 as before explained. The liquid is 'ma' tained at a constant level by a float valve 60 whichcontrols the iiow through the pipe 25 which connects this reservoir R. with the supply tank T.

As here shown the reservoir R is provided with cooling coils 56, and a motor driven pump 59 supplies a constant flow of liquidfrom this reservoir R to the spray ring 5| in the scrubber S for the purpose o'f condensing a part of the hydrocarbon vapors entering through the pipe 49. Such scrubbers are usually provided with baffles, screens or other suitable expedients, and in the screens 52 through the reservoir below. Passing through the center oi the scrubber is a vertical pipe 53 which connects to the center of a spiral passage 54 which has a'liquid seal at the level ofthe liquid in the -reservoir and an intake at 55 lin the scrubber.

Any uncondensed hydrocarbons and any gases enter this intake and are carried around the them from suspended These vapors and gases then pass through the pipe 53 and pipe 50 to the condenser C where the hydrocarbon vapors` are condensed to liquid and returned to the reservoirR through the pipe 6|, and the gases are passed out through the pipe 62 to the pump 33 'or else are metered at N as a by-product having considerable fuel value.

As previously explained, the thermal reduction products produce Vsuflicient blastin the fluev F to", satisfactorily atomize the hydrocarbon liquid sprayed intothe flue through the pipe 28 and spray channel V; however, this atomization may be enhanced by recirculating the gases' from the condenser C through vthe pump r33'and pipe 32- to'the spray channel U in the flueF. In' the more hydrogen than carbon monoxide and there is also present some methane and minor amounts of other hydrocarbon gases; and since the shock cooling instantly dilutes these gases with several times their volume of hydrocarbon vapors, the percentage of CO is kept fordsatisfactory reuse of these gases without resorting to any separating of the CO. Moreover, this recirculating of these gases does not result in any accumulating processes which do -not produce hydrogen and hydrocarbon gasesat the shock cooling zone. That is to say, that in the present process, the recirculatedfgases are the same identical gases which'are produced by the process and thereinstance there is shownv a number of which the liquid trickles to' suiliciently low to afpercentage of CO as in other the shock cooling temperature employed, the amount of thermal decomposition of the hydrocarbons is minor as compared to the present process which accomplishes the shock cooling by vaporization of most of the hydrocarbon liquid. Thus the present process -of shock cooling by vaporization lof most of the hydrocarbon liquid, produces enough hydrogen and hydrocarbon gases to alter the percentage of CO sufliciently for satisfactory recirculation of the intermingled gases for the purpose of atomizing the hydrocarbon liquid, the vaporization of which further dilutes the CO to Well within the range of successful operation.

The amount of hydrogen and hydrocarbon gases produced in the retorts Land M is not suicient for atomizing the sprayed liquid, however, these gases2 which contain no'CO are returned through the pipe |35 to the pump 33 and are all used for `atomizing in the flue F, the

additional gases necessary for the purpose being drawn into the pump 33 from the condenser C through the pipe 62, and the remainder of the now through the pipe 62 passes through the meter N and is collected as a by-product.

Summary The operation of the apparatus to perform the described process will be readily understood from the foregoing description, and it will of course be understood that the operation should be controlled so as to collect the thermal reduction products in the least amount of liquid which will afford sufficient Iluidity to readily pass through the separator. It will also be understood that diiferent liquid hydrocarbons will require a different cooling temperaturetoassure sufcient vaporization to leave the proper amount of unvaporized liquid for collecting, and that the amount of unvaporized liquid necessary for collecting will depend upon the amount of other solids which issue from the reduction furnace along with the Mg and CO, and that this factor will vary with different reduction furnaces or with the same reduction furnace from time to time for Various reasons. It will also be understood that the temperature of the spray liquid supplied through the pipe 28 has a direct effect on the cooling temperature in the flue F and that consequently the percentage vaporization of a constant rate of flow of spray liquid will vary in accordance with the temperature of the liquid and that therefore this factor is a part of the previously described control over the percentage of vaporization. n

Proper control in the various steps of the process, may be accomplished either manually or automatically, whichever mode is desired.

'I'he molding of the briquettes in the pans of the retort F is described as the preferred practice, however, the invention canbe successfully practiced by supplanting the described conveyor and pans with an endless belt of some heat resisting metal trained around pulleys. 'I'he fluid paste will readily lay on this belt and will carbonize into a porous strip, which will break into pieces yof various sizes usually small, when the porous strip upon the belt starts around the pulley at the discharge end of the retort. When this practice is followed, the open ends of the cages |04 are formed with louvers or else with slots so as to more readily retain the small pieces of material, and still afford adequate passage of the It will ofcourse be understood that vbefore starting the operation of the equipment, it is necessary to displace the air in the system with some inert gas or vapor, This may be accomplished in any wellknown manner preliminary tionally occur with a reduced pressure Within thesystem. That is'to say, that with a slight pressure in the system, any unintended leakage will be an egress instead ,of an ingress; and ofcourse any ingress of air is 'not only detrimental, but

also dangerous because of the possibilities of explosions due to the highly combustible nature of the various'substances existing vin the process.

It will be readily understood that the process is directed to the commercial production of Mg from the well known MgO which has long been commercially obtained from magnesite deposits and other natural sources. `The present process is readily adaptable to large scale, production of Mg from MgO at a cost comparing favorably to the cost of anhydrous electrolysis of MgCl obtained from the well known magnesium bitterns or else from magnesium brines. w

Where it is desired to collect the Mg and other solids in dry form, the shock cooling is accomplished by complete vaporization of a suitable hydrocarbon liquid sprayed into the flue vI at the required rate. In such instances, the separator G is replaced byv any suitable filter which will separate the solids from thevapors and gases,` and the Mg is then recovered by distillation in any suitable manner.

The separator shown at G is made the subject of a separate application Serial No. 473,324 led January 23, 1943; and the automatic reamer shown in Fig. 5 is made the subject of a separate application Serial No. 473,325 filed January 23, 1943. A

In the present application I claim as my invention:

1. A process for producing magnesium metal,

comprising thermal reduction of magnesium ox- 1de with carbon, wherein the magnesium occurs l in vapor form intermingled with carbon monox- `ide and some finely divided solids corresponding to the original reagents, condensing the magnevsium by a spray of hydrocarbon liquid at a rate ide with carbon, wherein the magnesium occurs y in vapor form intermingled with carbon monoxide and some nely divided solids corresponding to the original reagents, condensing the magnev sium by a spray of hydrocarbon. liquid at a rate circulating gas through the material in the sevto produce a shock cooling temperature at which all of the hydrocarbon liquid is vaporized except a limited amount suicient to form a fluid sprayed into the quetting and recovery ydensing.

paste with the magnesium and existing solids,

separating said paste from the vapors and gas,

next distilling the hydrocarbon liquid from Said' 3. A process for producing magnesium metal,

comprising thermal reduction of magnesium oxide with carbon, wherein the magnesium, occurs in vapor form intermingled with carbon monoxide and some nel'y divided solids corresponding to the original reagents, condensing the magnesium by a spray of hydrocarbon liquid at a rate to produce a shock cooling temperature at which all of the hydrocarbon liquid is vaporized, removing the vapors and gas from the Vmagnesium, and other solids, and recovering the magnesium by distillation and condensing.

4. The process of producing magnesium metal, comprising thermal reduction'of magnesium oxide With carbo-n to form magnesium vapor intermingled with carbon monoxide and some iinely divided solids corresponding to the original reactants, spraying into the magnesium vapor an inert liquid at a rate to produce a shock cooling temperature by vaporization of all of said liquid except an amount which will form a iiuid paste withthe magnesium and other solids, separating this paste from the vaporized liquid and gas, heating the paste to vaporize the liquid from the magnesium and other solids, distilling the magnesium from the other solids and condensing the v distilled magnesium, and recovering the vaporized liquid by condensation.

5. 'I'he process of producing magnesium metal, comprising thermal reduction of magnesium oxide with carbon to fform magnesium vapor intermingled with carbon-monoxide and some lfinely* .divided solids corresponding to the original reactants, spraying into the magnesium vapor an temperature by vaporization of such liquid, controlling the rate 'stant temperature which will' aflordA complete vaporization of the liquid so as to leave the magnesium and other solids in dry form, removing the vaporized liquid and gas, distilling the magnesium from the other ized liquid by condensation.

6. The process of producing magnesium metal which comprises, thermal reduction of magnesium oxide with carbon vapor and carbon monoxide', then shock cooling the magnesium vapor metal-by means thermal reduction products at a controlled rate in direct accord with the thermal reduction output and of such ratio thereto as will produce apredetermined constant temperature within the boiling point range o-f the hydrocarbon liquid employed so as` to be deterrninative of the extent of vaporization of the hydrocarbon liquid sprayed into the thermal reducof spray'so as to produce a consolids and condensing the distilled magnesium, and recovering the vaporto produce magnesiumy metal'whereinrthe magnesium occurs in vapor form in the presence of a gas and some finely divided solids, the improvement of collecting the magnesium 'and other solids inapproximately twice their weight of a hydrocarbon-liquid to v thereby form a fluid paste, which comprises spraying into the magnesium vapors a suitable hydrocarbon liquid at a rate to produce shock cooling by the vaporization of all of such hydrocarbonl liquid except the amount required to produce the fluid paste of aforesaid proportions, separating said paste from the vaporized hydrocarbons and' gas, condensing the vaporized hydrocarbons for repeated= use, distilling the unvaporized hydrocarbons from said paste to form a porous solid containing finely divided magnesium, distilling the magnesium from said porous solid, and condensing the distilled mag` nesium.

8. In a process for-producing magnesium metal wherein the magnesium occurs in vapor form in the presence of a gas and some nely divided I solids, the 'improvement of collecting -the magnesium and other solids in approximately twice their Weight of a hydrocarbon liquid to thereby form a fluid paste, which comprises spraying into the magnesium vapors a suitable hydrocarbon liquid at a rate to produce shock cooling by the vaporization of all of such hydrocarbon liquid except the amount required to produce the fluid paste of aforesaid proportions, separating said paste from the vaporized hydrocarbons and gas, condensing the vaporized hydrocarbons for repeated use, distilling the unvaporized-hydrocarbons from said paste While molding thelatter to form uncompressed porous cakes containing finely divided magnesium, distilling the magnesium from said porous cakes,

. form in inert liqu1d at a rate to produce a shock cooling to a lfinely divided solid of a suitable hydrocarbon. liquid tion products, maintaining said predetermined.'

constant temperature suciently high witnrelation to the boiling point yrange of the hydrocarbon 7. In a process for producing magnesium and condensing the distilled magnesium.

9. In a 'process for producing magnesium metal wherein the magnesium occurs in vapor the presence of carbon monoxide and some nely divided solids, the improvement of ,collecting the magnesium andother solids in approximately twice their weight of a hydrocarbon liquid to thereby form a fluid paste, which comprises spraying into the magnesium vapors a suitable hydrocarbon liquid at a rate to produce shock cooling|by the vaporization of all of y such hydrocarbon liquid except the amount required to produce the iluid paste of aforesaid proportions and at the same time produce vsome hydrogen and methane by thermal decomposition of the hydrocarbon liquid, then separating said paste from the vaporized hydrocarbons and gases, condensing the vaporized hydrocarbons for repeated use and utilizing said gases to atomize said spray of hydrocarbon liquid, distilling most of the unvaporized hydrocarbons from said paste to form a porous solid containing nely divided magnesium and at the same time produce some hydrogen and methane by thermal decomposition of the hydrocarbons, condensing said distilled hydrocarbons for repeated use and utilizing this hydrogen and methane as a vapor carrier'to accelerate distillaing some hydrogen and methane by thermal de-` composition of the existinghydrocarbon liquid,

condensing the distilled magnesium, and utiliz-` ing this hydrogen and methane as a vapor carrier to accelerate distilling of the magnesium.

10.`The process for producing magnesium metal, comprising thermal reduction to produce magnesium in vapor form, condensing the magnesium vapors by direct vaporization of a spray of hydrocarbon liquid at suilcient rate to produce a shock cooling temperature which will afford a dew point to preclude vaporization of vabout ten per cent of the hydrocarbon liquid employed, 'collecting the magnesium in the unvaporized portion as a -uid paste, subjecting said paste to a two stage distillation, first to distill oiT the hydrocarbons and then to distill the magnesium, and condensing the latter.

1l. The process for -producing magnesium,

point range of the hydrocarbon liquid employedv and sufficiently below the maximum boiling point of such liquid to'aiord a dew point ior i;

from five to ten per cent of the liquid employed,

` to thereby condense the magnesium in a limited amount of hydrocarbon liquid to form a uid paste, subjecting said paste to a two stage distillation, rst to distill oi the hydrocarbon liquid and then to distill the magnesium, -and condensing the distilled magnesium.

l2. A process for producing magnesium metal, comprising thermal reduction of magnesium oxide with carbon, wherein the magnesium ocshock cooling and at the same time produce an adequate amount of hydrogen and some methane ,by thermal decomposition of the hydrocarbons, controlling the rate of spray so that all of said hydrocarbon liquid is vaporized except an amount which will form a fluid paste with the magneksium and other solids, separating said paste from the vaporized hydrocarbons and gases, condens ing the Vaporized hydrocarbons for repeated use,

curs in vapor form intermingled with carbon ,l

` the magnesium vapors by directvaporization of a spray of hydrocarbon liquid at a rate to produce a shock cooling temperature within the boiling point range of the hydrocarbon liquid employed and suiiciently below the maximum boiling point of such liquid to afford a dew point for from ve to ten per cent of the liquid employed, to thereby collect the Amagnesium and other solids in a limited amount of hydrocarbon'liquid to form a fluid paste, subjecting said paste to a two stage distillation,v rst to distill off the hydrocarbon liqu'id and then to distill the magnesium, and condensing the distilled'rnagnesium.

13. A process for condensing hot metal vapor in the presence of a reactive gas, which comprises spraying into the hot metalvapor a hydrocarbo-n liquid at a controlled rate in direct relation to the temperature of said metal vapor and reactive gas and of such ratio thereto as lwill produce a constant shock cooling temperature at which more than ninety'per cent of the sprayed hydrocarbon liquid is vaporized, removing the vaporized hydrocarbons with the reactive gas and separating the latter by condensing the former, and recovering the metal by distillation and condensaton.

14. A process for condensing hot metal vapor in the presence of a reactive gas, which comprises spraying into the hot metal vapor a hydrocarbon liquid at a rate to produce a shock cooling temperature by complete vaporization of thehydrocarbon liqu.id, removing the vaporized hydrocarlions with the reactive gas and separating the latter bycondensing the former, and recovering the metal by distillation and condensation.

15. The process of producing magnesium metal, comprising thermal reduction of magnesium oxide with carbon to form magnesium vapor intermingled with carbon monoxide and some nely utilizing said gases to atomize said spray of hydrocarbon liquid, distilling most of the unvaporized hydrocarbons from said paste to form a porous solid containing nely divided magnesium and at the same time produce some hydrogen and methane by thermal decomposition of thevhydrocarbons, condensing said distilled hydrocarbons for repeated use and utilizing this hydrogen and methane as a Vapor carrier to accelerate distillation of said paste, distilling the magnesium from said porous solid and at the same time producing some hydrogen and methane by thermal decomposition of the existing hydrocarbon liquid, condensing the distilled magnesium, and utilizing this hydrogen and methane as a vapor carrier to accelerate distilling of the magnesium.

16. The process of producing magnesium metal,

comprising thermal reduction of magnesium oxide with carbon to form magnesium vapori intermingled with carbon monoxide and some nely divided solids correspondng to the original reactants, spraying into the magnesium vapors a suittrolling the rate of` spray so that all of said hydrocarbon liquid lis vaporized except an amount which will form a fluid paste with the magnesium and other solids, separating said paste from the.

vaporized hydrocarbons and gases, condensing the vaporized hydrocarbons for repeated use, utiv lizing said gases toatomize said spray of hydrodivided solids corresponding to the original ree suitable hydrocarbon liquid at a rate to produce carbon liquid, distilling the unvaporized hydrocarbons from said paste to form a porous solid' containing finely divided magnesium, distilling the magnesium, from said porous so1id,a.nd condensing the distilled magnesium. f

17. The process of producing magnesium metal, comprising thermal reduction of magnesiumv oxide with carbon to form magnesium vapor intermingled with carbon monoxide and some nnely divided solids corresponding to the original reactants, spraying into the magnesium vapor a. suitable hydrocarbon liquid at a rate .to produce shock cooling and at thel same time produce an adequate amount of hydrogen and some methane by thermal decomposition of the hydrocarbons, .'g' controlling the rate of spray vso as to vaporize all of said hydrocarbon liquid and leave the magnesium and other solids in dry form, removing' the vaporized hydrocarbons and said gases, separating the latter by condensing the former, utilizing said gases to atomize said spray of hydrocarbon liquid, and separating the magnesium from the other solids by distillation and condens ing.

v18. A process for condensing hot metal vapor in the presence of a reactive gas, which comprises spraying into the hot metal vapor a suitable hydrocarbonliquid at a rate to produce shock mal decomposition o1 the hydrocarbons, controlling the rate of spray so as to vaporize all of said .hydrocarbon liquid, removing the vaporized hy- 2,328,202 n drocarbonsand said gases, separating the latter ,with carbon to produce magnesium vapor and carbon monoxide, the step which comprises shock cooling the magnesium vapor to a neiy divided solid metal by means of a suitable hydrocarbon liquid sprayed into thel thermal reduction prod# ucts at a controlled rate so as to produce a predetermined temperature at which the vaporization o! the hydrocarbons will be suillciently adequate to leave the ma immediate briquetting tion and condensing.

gnesium in condition for and recovery by distilla- HENRY A. DOERNER.

It is hereby certified that errorl app/ears inthe printed specification ofthe above numbered patent requiring correction afs follows: Page l, first column, line 18, for "vfluicll read --flue--g pslge 10,'11rstV co1umn, line l5,

claim-lll, for "oo mpzl Fing' reed compxgllsing-q and that the egid Lettere( .,Patent should be rendi/with thi-{correction therei thatsthe eme :nn-yl -cozlxf' 'vom l'so the record pf the use 1n the Pgtqntfornce.' l l J Signed ee'aledth'is 50th dd? of November', A. D.' 1915.

Henry Vgn Arednle,

f (Seal) Aetlng'coemleeionerr Patente; 

